US6584434B1 - Method for data filtering and anomoly detection - Google Patents

Method for data filtering and anomoly detection Download PDF

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Publication number
US6584434B1
US6584434B1 US09/556,987 US55698700A US6584434B1 US 6584434 B1 US6584434 B1 US 6584434B1 US 55698700 A US55698700 A US 55698700A US 6584434 B1 US6584434 B1 US 6584434B1
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Prior art keywords
data
archiving
change
rolling
archived
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US09/556,987
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English (en)
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Louis Andrew Schick
Douglas Ancona Catharine
Stephen Duane Sanborn
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General Electric Co
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General Electric Co
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Assigned to GENERAL ELECTRIC COMPANY reassignment GENERAL ELECTRIC COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CATHARINE, DOUGLAS A., SCHICK, LOUIS A., SANBORN, STEPHEN D.
Priority to US09/556,987 priority Critical patent/US6584434B1/en
Priority to CA2377471A priority patent/CA2377471C/en
Priority to PCT/US2001/004088 priority patent/WO2001082144A2/en
Priority to CZ20014607A priority patent/CZ20014607A3/cs
Priority to EP01908978A priority patent/EP1410266A2/en
Priority to AU2001236779A priority patent/AU2001236779A1/en
Priority to KR1020017016478A priority patent/KR100779297B1/ko
Priority to JP2001579162A priority patent/JP2003535392A/ja
Priority to BR0106094-5A priority patent/BR0106094A/pt
Priority to RU2002101626/09A priority patent/RU2002101626A/ru
Publication of US6584434B1 publication Critical patent/US6584434B1/en
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    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
    • G05B19/408—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by data handling or data format, e.g. reading, buffering or conversion of data
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B23/00—Testing or monitoring of control systems or parts thereof
    • G05B23/02—Electric testing or monitoring
    • G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
    • G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
    • G05B23/0221—Preprocessing measurements, e.g. data collection rate adjustment; Standardization of measurements; Time series or signal analysis, e.g. frequency analysis or wavelets; Trustworthiness of measurements; Indexes therefor; Measurements using easily measured parameters to estimate parameters difficult to measure; Virtual sensor creation; De-noising; Sensor fusion; Unconventional preprocessing inherently present in specific fault detection methods like PCA-based methods
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2223/00—Signal processing; Details thereof
    • F23N2223/04—Memory
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2223/00—Signal processing; Details thereof
    • F23N2223/06—Sampling
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2241/00—Applications
    • F23N2241/20—Gas turbines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N5/00—Systems for controlling combustion
    • F23N5/003—Systems for controlling combustion using detectors sensitive to combustion gas properties
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N5/00—Systems for controlling combustion
    • F23N5/02—Systems for controlling combustion using devices responsive to thermal changes or to thermal expansion of a medium
    • F23N5/10—Systems for controlling combustion using devices responsive to thermal changes or to thermal expansion of a medium using thermocouples

Definitions

  • the present invention relates to data filtering and anomaly detection, and more particularly to improved change-detect data compressing using a rolling average of the data as a low pass filter and mode based statistical process control for anomaly detection.
  • Optimal operational characteristics for modern gas turbine systems include high operational efficiency, low exhaust and long operational life. To obtain these operational characteristics, monitoring the operational parameters of the gas turbine system becomes desirable.
  • data relating to the physical and operational conditions of the gas turbine system are collected and analyzed. The data are collected from a large number of locations on, in or near the gas turbine system to accurately assess the operational characteristics of the gas turbine system.
  • the data relating to the operational parameters are particularly meaningful when the data are collected at high frequencies (i.e., one data point every one or two seconds) and when the collected data are compared to historical data that has been archived and collected over a large temporal range (i.e., days, months or years).
  • Collecting data from a large number of locations at a high frequency presents many problems. For example, the total amount of data collected are very large. When the gas turbine system is located at a remote location, local archiving of the large amount of collected data becomes problematic. As such, the large amount of collected data typically requires expensive storage devices for proper data archiving. In addition, transmitting the large amount of collected data from the remote location to a central location requires a long transmission time. Therefore, the costs related to transmission of the data are high. Thus, it is desired to filter the data before archiving at the remote site and transmitting to a central location while maintaining the statistical and informational integrity of the total amount of collected data.
  • the data are analyzed to determine the overall operational characteristics of the gas turbine system.
  • the data are analyzed to determine the overall operational characteristics of the gas turbine system.
  • pinpointing the exact problem involves laborious troubleshooting.
  • the large amount of data from different locations becomes meaningless unless the data are correlated to an operational condition of the gas turbine system. Therefore, it is desired that the collected data be sorted and assessed to accurately pinpoint any potential problems relating to the operational conditions of the gas turbine system without the need for undue troubleshooting.
  • a method for filtering and determining anomalies of corrected data from a system under test comprises buffering the data from the system under test. Rolling averages of the buffered data are calculated wherein the calculation of the rolling averages low pass filters the buffered data. Change-detect compression is performed on the rolling averaged data, and the compressed data are archived.
  • the archived data are transmitted to a central location, and the transmitted data are received at the central location.
  • the received data are archived at the central location.
  • the archived data are gathered at the central location.
  • the gathered data are filtered into at least one subset that is differentiated by mode.
  • the at least one subset is corrected, and distributive statistics are calculated on the at least one subset to identify long-term anomalies in the at least one subset.
  • FIG. 1 illustrates a flow chart of one exemplary embodiment of a method for low pass filtering data collected from a system
  • FIG. 2 illustrates a flow chart of one exemplary embodiment of a method of mode based statistical process control to detect anomalies in the data collected from the operation of a system
  • FIG. 3 illustrates a flow chart of one exemplary embodiment of a method for filtering and detecting anomalies of the collected data from the operation of a system.
  • a gas turbine control system monitors exhaust gas thermocouples to determine the exhaust temperature of the gases exiting the gas turbine system.
  • the gas turbine control system uses the exhaust temperature to adjust various parameters relating to the operation of the gas turbine system, such as, for example, fuel intake, to maintain the highest operational efficiency with low exhaust emissions.
  • the present invention encompasses other types of monitored data, such as, for example, exhaust composition, bearing temperature, inlet filter pressure, wheel space temperature, fuel heating value, fuel composition, inlet air temperature, ambient temperature and vibration information.
  • the present invention encompasses systems other than a gas turbine system and expressly encompasses any other system under test in which the operational characteristics are monitored.
  • the monitored and collected data are compared to archived data to diagnose potential problems with the physical and operational characteristics of the gas turbine system.
  • mode based statistical process control is performed by filtering the data into subsets differentiated by mode.
  • the subsets of data are compared to archived data to detect abnormalities and/or anomalies. If an anomaly is detected in the subset of data, the abnormal operation can be pinpointed to a specific operational condition defined by the mode of the subset. Therefore, specific maintenance and/or service can be performed specified by the operational condition defined by the mode of the subset of data for which the anomaly was detected.
  • the gas turbine system itself includes approximately 200 sensors connected on, in or near the gas turbine.
  • the plant housing the gas turbine system can include over 1000 sensors.
  • the data are collected at a relatively high frequency from each sensor, such as, for example, one data point every two seconds. At this frequency, thirty data points are collected per minute and 1800 data points are collected per hour for each sensor in the gas turbine system. Therefore, in these embodiments, given a data measurement frequency of one data point every two seconds, the amount of data can range between about 360,000 to over 1,800,000 data points per hour.
  • the data can be collected until a predetermined number of data points are recorded.
  • the data are collected over a predetermined amount of time. It should be appreciated that the present invention encompasses data collected at higher or lower rates than one data point per every two seconds.
  • the gas turbine system is located remotely from a central location where the data analysis is performed.
  • the central location includes control and analysis equipment such as computers to control the operation of the gas turbine system and uses the collected data to perform statistical analyses.
  • the collected data are archived at the remote location and transmitted to the central location at a predetermined time interval.
  • the collected data are transmitted via a telephone connection. It should be appreciated that the data can be transmitted using other transmission techniques, and the transmission techniques are not limited to those disclosed herein.
  • the data are low pass filtered and used in change-detect compression. It should be appreciated that, for convenience, one embodiment is described using the collection and analysis of one portion of data. However, the embodiments discussed herein can be applied to the collection and analysis of all data collected from the gas turbine and/or the plant that houses the gas turbine system.
  • data from the gas turbine system are buffered (step 110 ) in raw form directly from the sensors.
  • the data are buffered at a frequency of one hertz.
  • the data are buffered in a dynamic memory device.
  • the data comprise a plurality of data points that relate to the operational and/or physical characteristics of the gas turbine system.
  • the oldest data point is dropped and a new data point is added to the four data points that are left.
  • the new five data points are averaged to produce a second rolling average. Again, the oldest data point is dropped, and a new data point is added to the four data points that are left.
  • the new five data points are averaged to produce a third rolling average.
  • This rolling average is continuously performed on the raw buffered data in the manner disclosed herein. It should be appreciated that the averaging of five data points is one embodiment, and the present invention expressly encompasses other numbers of data points used to calculate the rolling average. Performing the rolling average of the raw buffered data substantially reduces any high frequency random noise that is present in the data. Thus, the raw buffered data are low pass filtered by the calculation of the rolling average.
  • change-detect compression is performed on the rolling averaged data points (step 130 ).
  • the change-detect compression records data only when the current data point under evaluation has a change/delta that is larger than a predetermined change/delta.
  • the predetermined change/delta is termed as the zero band or dead band.
  • the rolling average of every five data points maintains the statistical and informational integrity of the total number of collected data points while the change-detect compression reduces the number of data points under analysis.
  • the combination of a five point rolling average with a two degree Fahrenheit statistical deviation results in a reduction from about 700 data points per hour (1 degree statistical deviation without rolling average) to about 20 data points per hour while preserving the informational content of the total amount of data. Therefore, the combination of the rolling average and the change-detect compression reduces the data required for analysis of the operational characteristics of the gas turbine.
  • the compressed, rolling averaged data are archived (step 140 ).
  • the data are archived over a predetermined amount of time.
  • the archiving of the data is performed in a dynamic memory location or on a magnetic media.
  • the compressed, rolling averaged data are transmitted, for example, to a central location (step 150 ).
  • the compressed, rolling averaged data are archived for two hours and then transmitted to the central location.
  • the data are transmitted via a telephone connection.
  • the data can be transmitted by other methods of transmitting data.
  • the data are transmitted (step 150 ).
  • the data are received at the central location (step 160 ).
  • the received data are archived at the central location (step 170 ). It should be appreciated that after the compressed, rolling averaged data are transmitted, the data that was archived at the remote location can be deleted or over-written with new compressed, rolling averaged data.
  • the received data are archived on a magnetic medium. It should be appreciated that statistical analysis may be performed on the archived data to further identify abnormalities and/or anomalies in the data that require further investigation.
  • anomalies in the data collected from the gas turbine system are detected using mode based statistical process control.
  • the high rate data are gathered from, for example, an archived location (step 220 ).
  • the data are collected from sensors monitoring the operation of the gas turbine system.
  • the data are provided after performing the rolling average and change-detect compression. It should be appreciated that, in a preferred embodiment, the anomaly detection is performed on archived data in a batch process, and the archived data are analyzed at various times after the data has been collected. As such, the gathering of the data (step 220 ) may be performed at a time later than the collection of the data from the gas turbine system.
  • the operational characteristics also relate to specific service and maintenance procedures relating to the operational characteristics of the gas turbine system. Once the data are correlated to an operational characteristic, a statistical analysis of the correlated data determines whether the particular service or maintenance procedures need to be performed.
  • the data points are filtered into subsets of data that are differentiated by mode (step 230 ).
  • the filtering of the data involves correlating similar data into subsets of data that relate to various operational characteristics, defined as modes, of the gas turbine system.
  • the operational characteristics or modes can be used to diagnose potential problems associated with the physical and operational conditions of the gas turbine.
  • a mode represents an operational characteristic or operating condition for which constant values are expected.
  • a mode represents an operational characteristic or operating condition for which a known deterministic function, such as a degradation slope, is expected.
  • a mode can comprise an operational characteristic or operating condition that is associated with a predetermined function performed by the gas turbine system, such as, for example, operational efficiency or vibrational characteristics of the gas turbine system.
  • data that relate to the exhaust temperature can be filtered into a subset of data and analyzed to determine changes in leakage flows that indicate wear in the combustion area of the gas turbine system.
  • data relating to the bearing metal temperature can be filtered into a subset and analyzed to determine changes in bearing loading and/or bearing casing slippage.
  • data relating to inlet filter pressure can be filtered into a subset and analyzed to determined whether the inlet filter requires cleaning or needs to be replaced.
  • data relating to wheel space temperature can be filtered into a subset and analyzed to determine problems with the wheel space of the gas turbine system that require immediate service. It should be appreciated that other data can be filtered into a variety of subsets based on mode and analyzed to determine the operational characteristics of the gas turbine system, and the present invention should not be limited only to those modes discussed herein.
  • the data are corrected to correct for ambient conditions and/or empirical or algorithm corrections (step 240 ).
  • the correction of the data points allows data collected over a variety of ambient conditions to be compared and analyzed.
  • descriptive statistics can be calculated on the subset of data (step 250 ).
  • the descriptive statistics can include a trend analysis, mean, standard deviation and [certosis] kurtosis.
  • long term abnormalities/anomalies of the operation of gas turbine system are identified (step 260 ). In one embodiment, the long-term abnormalities/anomalies are identified using control chart results on the subsets of data.
  • remedial service actions can be performed on the gas turbine system.
  • the remedial service actions relate to the operating condition identified by the mode of the subset of data.
  • the filtering of data into subsets and the statistical analysis of the subsets allows potential problems in the operation of the gas turbine system to be identified from the analysis of the data without undue manual troubleshooting.
  • data are buffered from the gas turbine system at a frequency of, for example, one hertz (step 310 ).
  • Rolling averages of the raw buffered data are calculated (step 312 ).
  • change-detect compression is performed on the rolling averaged data (step 314 ).
  • the change-detect compression has been explained herein above.
  • the compressed, rolling averaged data are archived at a remote location (step 316 ) when the gas turbine system is located remotely from a central location.
  • the compressed, rolling averaged data are transmitted (step 318 ).
  • the transmission of the average data points can be accomplished over, for example, a telephone connection or any other method of transmitting data.
  • the transmitted data are received at the central location (step 320 ).
  • the data are archived at the central location (step 322 ). After archiving, the data are gathered (step 324 ). The data are filtered into subsets of data differentiated by mode (step 326 ). Mode has been defined above. The subsets of data are corrected based on ambient conditions and/or empirical or algorithm corrections (step 328 ). Descriptive statistics are performed on the subsets of data (step 330 ). The descriptive statistics comprise, for example, trend analysis, mean, standard deviation, [certosis] kurtosis. Long term abnormalities/anomalies are identified in the subsets of data (step 332 ).
  • this exemplary embodiment filters the amount of data points while maintaining the statistical and informational integrity of the total amount of collected data.
  • the filtering of the data into subsets and the statistical analysis of the subsets allows for pinpoint diagnosis of the physical and operational conditions of the gas turbine system which promotes higher operational efficiency, lower emissions and longer operational life.

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Human Computer Interaction (AREA)
  • Manufacturing & Machinery (AREA)
  • Testing And Monitoring For Control Systems (AREA)
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US09/556,987 2000-04-24 2000-04-24 Method for data filtering and anomoly detection Expired - Lifetime US6584434B1 (en)

Priority Applications (10)

Application Number Priority Date Filing Date Title
US09/556,987 US6584434B1 (en) 2000-04-24 2000-04-24 Method for data filtering and anomoly detection
KR1020017016478A KR100779297B1 (ko) 2000-04-24 2001-02-08 데이터를 로우 패스 필터링하는 방법 및 모드 기반 통계 처리 제어 방법
PCT/US2001/004088 WO2001082144A2 (en) 2000-04-24 2001-02-08 Method for data filtering and anomaly detection
CZ20014607A CZ20014607A3 (cs) 2000-04-24 2001-02-08 Způsob filtrování dat a zjią»ování anomálií
EP01908978A EP1410266A2 (en) 2000-04-24 2001-02-08 Method for data filtering and anomaly detection
AU2001236779A AU2001236779A1 (en) 2000-04-24 2001-02-08 Method for data filtering and anomaly detection
CA2377471A CA2377471C (en) 2000-04-24 2001-02-08 Method for data filtering and anomoly detection
JP2001579162A JP2003535392A (ja) 2000-04-24 2001-02-08 データのローパスフィルタ処理方法、プロセス制御方法および異常検出の方法
BR0106094-5A BR0106094A (pt) 2000-04-24 2001-02-08 Método para filtragem de dados e detecção de anomalia
RU2002101626/09A RU2002101626A (ru) 2000-04-24 2001-02-08 Способ для фильтрации данных и обнаружения аномалии

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EP (1) EP1410266A2 (ko)
JP (1) JP2003535392A (ko)
KR (1) KR100779297B1 (ko)
AU (1) AU2001236779A1 (ko)
BR (1) BR0106094A (ko)
CA (1) CA2377471C (ko)
CZ (1) CZ20014607A3 (ko)
RU (1) RU2002101626A (ko)
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US20050069406A1 (en) * 2003-09-30 2005-03-31 Turnquist Norman Arnold Method and apparatus for turbomachine active clearance control
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JP4103467B2 (ja) * 2002-06-28 2008-06-18 株式会社日立プラントテクノロジー 機器メンテナンス診断システム
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KR20020031343A (ko) 2002-05-01
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WO2001082144A2 (en) 2001-11-01
WO2001082144A3 (en) 2004-02-26
RU2002101626A (ru) 2003-08-27
CA2377471A1 (en) 2001-11-01
BR0106094A (pt) 2002-02-26
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JP2003535392A (ja) 2003-11-25
CA2377471C (en) 2010-06-22

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